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GDIS2017
Evaluation of Die Wear with Stamping DP1180 Steel
Wei Wu1, Dajun Zhou2, Donald J. Adamski3, Darryl Young4, and Yu-Wei Wang1
1. AK Steel Corporation
2. FCA US LLC
3. GM Motor Company
4. Ford Motor Company
A/SP Stamping Tooling Optimization
#GDIS | #SteelMatters 2
Stamping Tooling Optimization Team Members
A/SP Project Lead: Donald Adamski– General Motors
A/SP Project Manager: Eric McCarty– A/SP
JPC Mentor: Jody Hall, SMDI
Name Company
Yueqian (Victor) Jia AK Steel
Ron Radzilowski AK Steel
Yu-Wei Wang AK Steel
Wei Wu AK Steel
Feng Zhu AK Steel
Sharon Clor Alro Steel Corporation
Peter Clifton ArcelorMittal
Darryl McCaleb ArcelorMittal USA
Sriram Sadagopan ArcelorMittal USA
Gang Huang ArcelorMittal USA
John Vecore III Dayton Progress
D. J. Zhou FCA US LLC
Name Company
Changqing Du FCA US LLC
Constantin Chiriac Ford Motor Company
Darryl Young Ford Motor Company
Carol Malfroid Ionbond
Andy Thompson Nucor
Arnie Newsome Nucor
Hokook Lee POSCO America
Jim Van Epps Uddeholm
Xueyuan Nie University of Windsor
Gene Hsiung GM
Ken Schmid GM
Carolyn Philpott SMDI
Tamara Markarian SMDI
#GDIS | #SteelMatters 3
Introduction
Objectives: • Study die wear durability of various tooling materials and coatings for
flanging operations on bare DP1180 steel.
• Update OEM tooling standards based on the test results.
Project Phases: • Phase 1: Can we use the current die materials and
coatings in production of 980 grade steels? (2015)
• Phase 2: If not, what die materials and coatings should we
use to form 1180 grade steels? (2016)
• Phase 3: Why did some of the die inserts perform better
than others? (Ongoing……)
100 %
100 %
30 %
#GDIS | #SteelMatters 4
Experimental Material: Bare DP1180
Sample
Orientation
Yield Strength
(MPa)
Ultimate Tensile
Strength (MPa)
Uniform
Elongation (%)
Total
Elongation
(%)
L 919 1182 5.6 10.6
T 926 1212 5.1 8.8
D 909 1198 5.4 10.4
The phase volume fraction of martensite
was found to be approximately 70 %.
1.2 mm Thickness
Dark color: Martensite
Light color: Ferrite
#GDIS | #SteelMatters 5
Die Wear Experiment in Production Environment
• Over 100k hits;
• 33 die inserts;
• Combination of
10 die materials
and 9 coatings;
• 42 Ton testing
materials;
• Preserve one
panel every 500
hits;
#GDIS | #SteelMatters 6
Progressive Die Setup
Lower Die Upper Die
Contact points
#GDIS | #SteelMatters 7
Progressive Die Setup
#GDIS | #SteelMatters 8
Forming Simulation for Progressive Die Wear
A “worst” case scenario: 1. Relative aggressive die insert design;
2. Uncoated sheet metal;
3. No lubrication.
#GDIS | #SteelMatters 9
2015 Progressive Die Wear Experiment Matrix
12 11 10 9 8 7 6 5 4 3 2 1
Die
Mater. CC1 S0050A S0050A S2333 TD2 TD2 DC53 TD2 TD2 T44 CC1 D6510
Coating HVOF
MPD
Cr Plate
over Ion
Nitride
Cr Plate PVD
Duplex
CrN
Concept Cool Sheet PVD
Duplex
CrN
PVD
Duplex
CrN
PVD
Duplex
CrN
PVD
Duplex
CrN
PVD
Duplex
CrN
PVD
Duplex
CrN
Hardness (Rc) 54-58 38-43 54-58 40-45 55-60 55-57 55-60 55-57 55-58 44-46 38-42 54-58
12 11 10 9 8 7 6 5 4 3 2 1
Die
Mater. D2
(NEW)
D2 (NEW) D2 (NEW) TD2
(NEW)
D2 (NEW) D2 (NEW)
Coating PVD
Duplex
CrN
PVD
Duplex
CrN
PVD
Duplex
CrN
Concept +
Most
PVD
Duplex
CrN
PVD
Duplex
CrN
Hardness (Rc) 58-60 58-60 58-60 58-60 58-60 58-60
NO. 1, 2, 8, 10, 11, and 12 were replaced by new
inserts after 15,000 hits The combinations of 8 die materials and 7 coatings were evaluated up to 20k hits.
#GDIS | #SteelMatters 10
2015 Progressive Die Wear Experimental Results
Safe
Rough
Very Rough
L R
#GDIS | #SteelMatters 11
2016 Progressive Die Wear Experiment Matrix
12 11 10 9 8 7 6 5 4 3 2 1
Die
Mater. SLD-i TD2 DC53 Cast
Caldie
TD2 TD2-old TD2 SLD-i Toolox 44 Cast
Caldie
S2333
S2333
Coating Concept
+ most
Duplex
Variantic
Concept +
most
Concept +
most
Duplex CrN
+ most
Cool
sheet
Concept
+ most
Cool sheet
Cool sheet
Cool sheet
Cool sheet Cool sheet
Hardness (Rc) 58-62 55-58 62-64 58-62 55-58 55-57 55-58 58-62 - 58-62 50-54 40-45
14 and 16
Die
Mater. TD2
Coating Concept +
most
Hardness (Rc) 55-58, N.A.
15
Die
Mater. S2333
Coating Concept +
most
Hardness (Rc) 40-45
13
Die
Mater. TD2
Coating Concept
(only)
Hardness (Rc) 55-58
No. 8 was replaced by
No. 14 after 4,000 hits
No. 3 was replaced by No. 13;
No. 5 was replaced by No. 15;
No. 14 was replaced by No. 16;
After 70,000 hits The combinations of 8 die materials and 5 coatings were evaluated up to 85.8k hits.
#GDIS | #SteelMatters 12
2016 Progressive Die Wear Experimental Results
Safe
Rough
Very Rough
L R
7 11 10 9
#GDIS | #SteelMatters 13
Roughness Measurements using Wyko Machine As-received Sheet Sample
WYKO NT1100
VSI mode
Objective: 10X
FOV: 5X
Long wave length cutoff: 800 μm
Short wave length cutoff: 8 μm
Stylus Pc height: 1.25 μm
Mapping area: 5 x 10 mm2
Ra: 1.83 μm
#GDIS | #SteelMatters 14
Roughness Measurements using Wyko Machine
Insert 5, SLD-i + Cool Sheet
L
Failed at 50k hits
R
L
L
#GDIS | #SteelMatters 15
Roughness Measurements using Wyko Machine
Insert 5, SLD-i + Cool Sheet
Mapping area: 1.2 x 5 mm2
Ra: 9.69 μm (1.83 μm)
L R
L
L
Failed at 50k hits
#GDIS | #SteelMatters 16
Roughness Measurements using Wyko Machine
Insert 7, TD2 + Cool Sheet
L R
L
L
No Failure
after 100.8k hits
#GDIS | #SteelMatters 17
Roughness Measurements using Wyko Machine
Insert 7, TD2 + Cool Sheet
Mapping area: 1.2 x 5 mm2
Ra: 1.19 μm (1.83 μm)
L R
L
L
No Failure
after 100.8k hits
#GDIS | #SteelMatters 18
Roughness Results after 100,800 hits
Roughness on formed panel
#GDIS | #SteelMatters 19
2016 Die Wear Performance: Crack Initiation Resistance
7
11
10
9
#GDIS | #SteelMatters 20
2016 Die Wear Performance: Crack Propagation Resistance
9
7
#GDIS | #SteelMatters 21
2016 Die Wear Overall Performance
7
11
10
9
2L 4R 6R
6L
2R 4L
#GDIS | #SteelMatters 22
Correlation Between Die Wear and Roughness
#GDIS | #SteelMatters 23
Correlation Between Die Wear and Hardness
> 54 Rc < 54 Rc
#GDIS | #SteelMatters 24
Correlation Between Die Wear and Radius > 5.9 mm
4 ~ 5 mm 5 ~ 5.9 mm < 4 mm
11
7
10
9
The design radii:
2.8 mm.
#GDIS | #SteelMatters 25
The Factors Influencing Die Wear Performance
Die Wear
Die Material
Coating Method
Die Design
Die Manufacturing
Surface Roughness
Alignment & Clearance
#GDIS | #SteelMatters 26
Conclusions • The die material and coating method in large volume production of 980
and lower grades steels was not suitable for forming next generation
AHSS, 1180 grade steels.
• The die materials, such as ductile iron and low alloy cast steel, should
not be considered for die design in stamping 1180 grade steels.
• The inserts #7 (TD2, Cool Sheet), 9 (Cast Caldie, Concept+Most), 10
(DC53, Concept+Most), and 11 (TD2, Duplex+Variantic) are the
potential candidates for stamping 1180 grades steel in mass
production.
• The die wear performance was influenced by combination of die
material selection, die material hardness, die design, coating method,
die surface roughness, die insert manufacturing, die alignment, and
AHSSs.
#GDIS | #SteelMatters 27
For More Information
Wei Wu
AK Steel Corporation
313-317-1298
Dajun Zhou
FCA US LLC
248-944-1197
Donald J. Adamski
General Motors Company
586-596-2533
Darryl Young
Ford Motor Company
313-805-8299
Yu-Wei Wang
AK Steel Corporation
313-623-4942
